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Transmission Reassembly: Notes

NOTE: Ensure needle roller bearing is installed into input shaft and 4th gear synchronizer ring is installed at this time.
  1. Install countershaft, input shaft and output shaft assemblies into transmission case through top opening. See Fig 1-Fig 3 .
  2. Mate input and output shaft assemblies by positioning them at an upward angle and setting them together. Install output shaft bearing using a brass drift. Ensure center bearing outer races are squarely positioned in bores. Install countershaft center bearing.
    Fig 1: Installing Countershaft Cluster Gear
    G00380267Courtesy of MAZDA MOTORS CORP.
    Fig 2: Installing Input (Primary) Shaft
    G00380268Courtesy of MAZDA MOTORS CORP.
    Fig 3: Installing Output Shaft
    G92G13892Courtesy of MAZDA MOTORS CORP.
  3. Position center bearing cover to transmission case with reference arrow pointing upward. See Fig 4. Tighten center bearing cover bolts to specification. See TORQUE SPECIFICATIONS .
    Fig 4: Identifying Rear Bearing Retainer Cover Arrow
    G00380269Courtesy of MAZDA MOTORS CORP.
    4. NOTE: If any input shaft, output shaft or countershaft related components are replaced, end play must be readjusted. See INPUT SHAFT END PLAY .
  4. Install countershaft front bearing by hand. Apply grease to shim, bearing cover and oil baffle to retain them in position during assembly. Install shim with groove showing. Install spacer to transmission case countershaft front bearing bore.
  5. Tape input shaft splines along their entire length to prevent damage to oil seal lip. Apply a thin coat of lubricant to front cover oil seal lip. Apply 1/8" bead of sealant to front cover and retaining bolt threads. Install front bearing cover. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install oil through in upper transmission case. Install oil trough bolt and tighten.
  6. Install output shaft 5th gear. Install race and 5th gear split bearing on countershaft. Install countershaft 5th gear. Position counter lever shaft and plate and install counter lever shaft bolt.
  7. Install 5th-Reverse shift lever and install retaining ring. Install countershaft 5th gear synchronizer blocking ring. Position 5th-Reverse shift rail, shift fork and synchronizer, with reference mark on synchronizer sleeve facing reverse gear. Install retaining bolt in side of case.
  8. Install synchronizer split washer. Check clutch hub end play by measuring with a feeler gauge at split ring. See Fig 5. If clutch hub end play is not 0.0-0.002" (0.0-0.05 mm), select and install proper size split washer.

    Countershaft Split Washer Selection

    • 0.118" (3.00 mm)
    • 0.120" (3.05 mm)
    • 0.122" (3.10 mm)
    • 0.124" (3.15 mm)
    • 0.125" (3.20 mm)
    • 0.127" (3.25 mm)
    • 0.129" (3.30 mm)
    • 0.131" (3.35 mm)
    • 0.133" (3.40 mm)
    • 0.135" (3.45 mm)
    • 0.137" (3.50 mm)
    Fig 5: Measuring Clutch Hub End Play
    G98G03313Courtesy of FORD MOTOR CO.
  9. Install countershaft reverse gear. Install 2 countershaft reverse gear bearings. Install reverse synchronizer blocking ring.
  10. Check countershaft reverse gear end play by installing thrust washer, and hold forward pressure while measuring end play with feeler gauge between countershaft reverse gear and thrust washer. End play should be 0.010-0.014" (0.25-0.35 mm). Replace thrust washer to obtain proper end play.

    Countershaft Reverse Gear Thrust Washer Selection

    • 0.289" (7.35 mm)
    • 0.293" (7.45 mm)
    • 0.297" (7.55 mm)
    • 0.301" (7.65 mm)
    • 0.305" (7.75 mm)
    • 0.309" (7.85 mm)
  11. Install output shaft spacer. Install output shaft reverse gear. Install reverse idler gear and bushing. Apply suitable Teflon sealant to reverse idler shaft bolt and install bolt within 4 minutes of applying sealant. Using suitable collar and tube assembly, install output shaft bearing.
  12. Install thrust washer and countershaft rear bearing. Slide 1st-2nd and 3rd-4th synchronizer sleeves forward to lock transmission into 1st and 3rd gear. With mainshaft lock nut wrench, install NEW output shaft rear bearing lock nut. Install NEW countershaft lock nut. Tighten lock nuts to specification. See TORQUE SPECIFICATIONS . Stake lock nuts to bottom of shaft.
  13. Install speedometer drive gear on output shaft with snap ring. Apply 1/8" bead of sealant to case, and install transmission extension housing. With extension housing seal replacer, install NEW extension housing seal. Place synchronizer sleeves in neutral position. Apply sealant to mating surface of case cover, and install case cover. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill transmission with appropriate automatic transmission fluid. See RECOMMENDED FLUID  under LUBRICATION.
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